construction materials e-book
TRANSCRIPT
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All rights reserved to Civil EngineeringDepartment Ports, Customs & Free Zone
Corporation, Dubai. No parts of this
publication may be reproduced, stored
in any retrieval system, or transmitted in
any form or by any means, electronic,
mechanical, photocopying, recording orotherwise, without the prior consent of
the copyright owner.
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CONSTRUCTION MATERIALS
QUALITY CONTROL GUIDELINES
Ports, Customs & Free Zone Corporation, DubaiUnited Arab Emirates
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Al rights reserved to Civil Engineering Department Ports, Customs & Free Zone Corporation, Dubai. No parts of this publication may
be reproduced, stored in any retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying,recording or otherwise, without the prior consent of the copyright owner.
First Edition-2007
Construction Materials Quality Control Guidelines
This edition was issued in March 2007
Jebel Ali, Dubai, United Arab Emirates
P.O. Box 17000, Ports, Customs & Free Zone Corporation, DubaiTel.: 00971 4 8819444E-mail: [email protected]://ced.dubaitrade.ae
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CONSTRUCTIONMATERIALS
QUALITY
CONTROL
GUIDELINES
First Edition-2007
Ports, Customs & Free Zone Corporation, DubaiUnited Arab Emirates
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ACKNOWLEDGEMENT
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ACKNOWLEDGEMENT
The publication of this book could not have been possible but
for the ungrudging efforts put in by the Quality Section of the
Civil Engineering Department. We would like to acknowledge
contributions made by Group Internal Audit and Quality
Director, Nakheel Contracts and Procurement Manager,
Nakheel Quality Assurance Manager, Concrete Readymix
Suppliers, Materials Testing laboratories and many engineers
from different organizations.
Our thanks go out to all of those who contributed, whether
through their comments, feedbacks, edits or suggestions.
As there is always room for improvement, Civil Engineering
Department welcomes comments on this Book, and will
consider all that are received. Your comments will continue the
development of this book leading to its ultimate acceptance.
As always it has been a great joint effort..
Nazek Al Sabbagh
Chief, Civil Engineering Officer
Ports, Customs & Free Zone Corporation CED
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Page
Chairman Quality Policy Statement-------------------------------------------- 11
Section 1: Introduction------------------------------------------------------------------ 13
Section 2: Quality Control (General)----------------------------------------------- 15
2.01 Quality Policy -------------------------------------------------------- 15
2.02 Submittals ---------------------------------------------------------------- 15
2.03 General Quality Control Requirements------------------------------- 16
2.04 Quality Control Plans--------------------------------------------------- 19
2.05 Inspection Procedures--------------------------------------------------- 20
2.06 Inspection and Test Plan------------------------------------------------ 222.07 Document and Submittal Control------------------------------------- 22
2.08 Identification and Control of Items and Materials------------------- 23
2.09 Inspections and Tests---------------------------------------------------- 24
2.10 Measuring and Test Equipment---------------------------------------- 26
2.11 Non-Conformance Monitoring---------------------------------------- 26
2.12 Personnel Qualifications------------------------------------------------ 28
2.13 Quality Control Reports/Audits---------------------------------------- 28
2.14 Equipment/Material Handling and Storage-------------------------- 29
2.15 Quality Control Records------------------------------------------------ 292.16 Workmanship------------------------------------------------------------ 30
2.17 Protection of Property--------------------------------------------------- 31
2.18 QA/QC Induction Training--------------------------------------------- 32
Section 3: Recommended Practices Before and During Concreting----- 33
3.01 Formwork ---------------------------------------------------------------- 33
3.02 Concrete Consolidation ----------------------------------------------- 33
3.03 Concreting -------------------------------------------------------------- 333.04 Hot Weather Concreting----------------------------------------------- 34
Section 4: Schedule of Tests and Inspections-------------------------------- 37
a. Cast In-Situ Concrete (Ready-Mixed Concrete) ----------------------- 37
Laboratory and Plant Trial Mixes ------------------------------------ 37
Concrete Production & Site Deliveries ------------------------------- 39
Site Laboratories ------------------------------------------------------- 42
Aggregates ------------------------------------------------------------- 44
Water --------------------------------------------------------------- 46
Cementitious Materials and Admixtures ---------------------------- 47
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b. Bored In-Situ Piles & Drilled Shafts ------------------------------------- 48
c. Reinforcing Steel -------------------------------------------------------- 49
d. Epoxy-Coated Steel ------------------------------------------------------- 50
e. Earthwork ------------------------------------------------------------------ 51
f. Precast Concrete -------------------------------------------------------- 52
g. Glass Reinforced Cement (GRC) Elements ---------------------------- 53
h. Blocks ---------------------------------------------------------------------- 54
Concrete Blocks-------------------------------------------------------- 54
Autoclaved Aerated Concrete Blocks -------------------------------- 55
Normal Weight Polystyrene Sandwich Blocks----------------------- 56
Light Weight Masonry Units ------------------------------------------ 57 Clay Masonry Blocks with Polystyrene Insert ----------------------- 58
i. Lath and Plaster ----------------------------------------------------------- 59
j. Polystyrene Thermal Insulation ------------------------------------------ 60
k. Painting -------------------------------------------------------------------- 61
Section 5: QC Forms ------------------------------------------------------------- 63
a. Non-Conformance Report ----------------------------------------------- 63
b. Status of Non-Conformance Reports ----------------------------------- 64
c. Field Memorandum ------------------------------------------------------- 65d. Material Inspection Report ----------------------------------------------- 66
e. Notification of Material Receipt ---------------------------------------- 67
f. Inspection and Test Plan------------------------------------------------- 68
g. Concrete Pour Record --------------------------------------------------- 69
h. Inspection Record for Structural Repairs ------------------------------- 70
i. Pile Record ----------------------------------------------------------------- 71
Section 6: QC Checklists -------------------------------------------------------- 73
Introduction -------------------------------------------------------------------- 73
a. Pre-Concrete Checklist --------------------------------------------------- 74
b. Pile Cap -------------------------------------------------------------------- 75
c. Footings -------------------------------------------------------------------- 76
d. Tie Beams ------------------------------------------------------------------ 77
e. Slab on Grade ------------------------------------------------------------ 78
f. Walls ----------------------------------------------------------------------- 79
g. Columns ------------------------------------------------------------------- 80
h. Slabs ----------------------------------------------------------------------- 81
i. Reinforced Concrete Water Tanks--------------------------------------- 82
j. Water Proofing ------------------------------------------------------------ 83
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k. Back Fill ------------------------------------------------------------------- 84
l. Block Work --------------------------------------------------------------- 85
m. Plastering ----------------------------------------------------------------- 86
n. Roof Water Proofing ----------------------------------------------------- 87
o. Swimming Pool ----------------------------------------------------------- 88
p. Ceramic Tiles ------------------------------------------------------------- 89
q. Marble/Granite ---------------------------------------------------------- 90
r. Aluminium ---------------------------------------------------------------- 91
s. Painting (Metal Surfaces)------------------------------------------------ 92
t. Painting (Concrete/Plaster Surfaces) ----------------------------------- 93
u. Painting (Timber Surfaces) ---------------------------------------------- 94
v. False Ceiling ------------------------------------------------------------- 95w. False Ceiling Closure ---------------------------------------------------- 96
TABLE OF CONTENTS
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CHAIRMAN QUALITY POLICY STATEMENT
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The need for and use of a Quality control function can not be
overemphasized. Quality cannot be tested nor inspected into a product,
it must be built in. This manual outlines the basic and minimumrequirements for building a simple but effective system for controlling
the quality of work and basic materials used in construction. This manual
is based on the belief that:
Quality is controlled by adequate advance planning, coordination,
supervision, and technical direction; proper definition and a
clear understanding of job requirements and procedures; and
the employment of appropriately skilled personnel.
Quality is verified through checking, reviewing and monitoring
of work activities, with documentation by experienced, qualified
individuals who are not directly responsible for performing the
work.
Quality is achieved by providing proper training of personnel
and ensuring that all personnel remain current on the knowledge
and skills needed for their positions.
Quality is achieved by focusing on preventing problems or errors
rather than reacting to them.
Quality control should ensure that the work is done correctly the
first time.
This manual requires the attention and cooperation of all consultants,
contractors and production personnel to assure quality production and
material. It shall be implemented by all concerned parties in the field of
construction. All involved parties shall comply with quality issues in other
regulatory agencies having jurisdiction over the project.
Section 1: INTRODUCTION
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2.01 QUALITY POLICY
A. The Port, Customs and Free Zone Corporation Quality Policystatement signed by the Chairman will be adopted for allProjects.
B. The Project shall prepare a Statement of Commitment to thePort, Customs and Free Zone Corporation Quality Policy thatshall be signed by the Project Manager/Contractor Managerand Sub-Contractor Manager.
2.02 SUBMITTALSA. Contractors Quality Control Plan (QCP).
1. Submit to Employer Representative no later than 7 calendardays from issue of the commencement date.
2. No work covered by the Contractors QCP shall beginuntil the plan has been approved.
3. Plan shall describe all of the Contractors quality controlprocedures that will be used throughout the project.
4. Include an Internal and External Audit Schedule
a. Minimum requirements shall be as specified herein.
B. Quality Control Organization Plan
1. Show organization of Contractors quality control team.
2. Provide the name, qualifications, and experience of theQuality Control Manager and key QC support staff forapproval by the Employers Representative.
a. Once approved, the Contractors Quality ControlManager shall have full authority to represent and act forthe Contractor on all quality related matters.
b. Notify the Employer Representative in writing priorto re-assigning any of the designated quality control
personnel.c. Obtain Employer Representatives approval for
replacement prior to re-assigning or re-locating approvedquality control personnel.
C. List of Proposed Suppliers and Sub-Contractors QC Staff
1. List shall include the following:
a. Items to be supplied by each supplier and sub-contractor
b. Model or catalogue numbersc. Specifications
d. Inspection and test requirements
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e. Performance data
f. Anticipated inspection and test dates
g. Name and location of quarries and procedures forwork in quarries
2. List other pertinent information as appropriate.
D. Submit inspection and test results, certificates of compliance, andcertified material test reports to the Employer Representative.
E. Inspection and Test Plan
1. Submit to Employer Representative no later than 7 calendardays from the commencement date.
2. No work covered by the inspection and test plan shallbegin until the plan has been approved.
F. Quality Control Procedures and Instructions
1. Submit to Employer Representative no later than 3 calendardays prior to using such procedures or instructions.
2. Do not begin work governed by Quality Control Proceduresuntil such procedures have been approved by the EmployerRepresentative.
G. Records Index
1. Prepare an index of all project records which will bedeveloped and maintained during progress of the Work.
2. Submit to Employer Representative no later than 7 calendardays from the commencement date.
H. Inspection and Test Results
1. All materials delivered to the site shall be sampled andtested; test results to be submitted at least 7 calendar daysprior to incorporating items into the Work.
2. Report results to the Employer Representative indicatingcompliance or failure immediately upon receipt.
2.03 GENERAL QUALITY CONTROL REQUIREMENTS
A. Develop, implement and maintain a quality control programconsistent with the requirements of this Section.
1. Ensure equipment and material conform to applicablerequirements of each section of the specifications.
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2. Maintain specified quality in all areas of the Work includingbut not limited to:
a. Design and construction of temporary structures
b. Inspection
c. Testing
d. Packaging, shipping, handling and storage ofequipment and materials
e. Site construction activities
B. Establish procedures to prevent deficiencies from occurring.
1. Identify discrepancies when they do occur and then takecorrective action.
2. Instruct workmen, sub-contractors, material suppliers,and other personnel involved in the project on the correctprocedures to follow.
C. Assign specific responsibility for implementing the qualitycontrol program.
D. Systematically verify compliance with the specified requirementsusing quality control audits for sub-contractors and suppliers.
1. Record results in formal reports.
2. Establish corrective action logs to track all actions.
E. Assist Employer Representative in auditing quality controlactivities.
1. Employer Representatives audits may be either pre-
planned or random as warranted by general qualitytrends.
F. Inspect and test all work under this Contract.
1. Maintain records of such inspections and tests.
2. Prepare and submit signed checklists for all work offeredfor the approval of the Employers Representative.
G. Arrange for factory inspections and tests when required by theContract Documents.
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H. Provide equipment, instruments, qualified personnel, andfacilities necessary to inspect the work and perform the testsrequired by the Contract Documents.
I. Repeat tests and inspections after correcting non-conformingwork until all work complies with the contract requirements.
1. All re-testing and re-inspections shall be performed at noadditional cost to the Employer.
J. The Employer Representative may elect to perform additionalinspections and tests at the place of the manufacture, the
shipping point, or at the destination, to verify compliance withapplicable Specifications.
1. Inspections and tests performed by the EmployerRepresentative shall not relieve the Contractor of hisresponsibility to meet the Specifications.
2. Inspections and tests by the Employer Representative shallnot be considered a guarantee that materials delivered ata later time will be acceptable.
K. Non-conforming materials, whether in place or not, will berejected by the Employer Representative.
1. Contractor shall be notified in writing to correct or removethe defective material from the Works.
2. If the Contractor fails to respond, the EmployerRepresentative may order correction, removal, and/orreplacement of defective materials by others.
a. Contractor shall bear all costs for such work.
L. Materials accepted on the basis of a Certificate of Compliancemay be sampled and inspected/tested by the EmployerRepresentative at any time.
1. The fact that the materials were accepted on the basis ofa certificate of compliance shall not relieve the Contractorof his responsibility to use materials which comply with theSpecifications.
M. Contractor shall impose all of the specified QCP requirements(including inspection and test procedures) upon Suppliers andSub-Contractors.
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N. Failure to Perform
1. In the event the Contractor fails to adequately performany or all of the provisions of this Section, the Employer, athis sole discretion, reserves the right to have the EmployerRepresentative perform any or all of the provisions of thisSection and back-charge the Contractor for the actualcost of such work and any administrative charges deemednecessary.
2. This remedy for Contractors failure to perform shall be inaddition to any other right or remedy available under theContract.
2.04 QUALITY CONTROL PLAN
A. Provides detailed description of procedures, instructions,and reports used to ensure compliance with the ContractDocuments.
B. No construction shall begin and no requests for payment shallbe processed until the Contractors Quality Control Plan isapproved.
C. Contractors QCP shall include the following as a minimum:
1. Statement of Commitment to Ports, Customs & Free ZoneCorporation Quality Policy signed by all parties in theproject.
2. Organization chart identifying all personnel responsiblefor quality control.
a. Identify the manager of the QC program showing thatthe position is independent of the job supervisory staff
with clear lines of authority.
b. The QC manager shall report directly to the Contractorscorporate management and he shall liaise andcoordinate directly with the Employer Representative.
c. Show area of responsibility and authority of eachindividual in the quality control system.
d. Describe in detail the area of responsibility and authorityof each individual in the quality control system.
e. The QC manager or designated substitute shallbe present at the project site at any time work is inprogress.
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3. Procedures for reviewing shop drawings, samples,certificates, and other submittals necessary for contractcompliance.
a. Include the name of all personnel authorized to signthe submittals for the Contractor certifying that theycomply with the Contract requirements.
4. Procedures used to ensure compliance with the ContractDocuments, as well as problem identification, reportingand resolution.
a. Include a copy of forms and reports used to documentquality control operations.
b. Include a submittal status log listing required submittals
and action required by the Contractor and EmployerRepresentative or Project Manger.
5. A description of the services provided by outsideorganizations such as testing laboratories, architects, andconsulting engineers.
6. A test and inspection schedule keyed to the constructionschedule and following the order of the Specification.
Indicate the following:
1. Inspections and tests required.
2. Names of responsible personnel for each segment ofthe Work.
3. Schedule for each inspection and test.
4. Acceptance criteria for any tests carried out.
7. Document and submittal control procedures.
8. Procedures to identify and control use of items andmaterials.
9. Sample forms to be used (Stop Work Order, NCR, etc.)10. A control chart for both production facilities and field
operation to provide a visual indication of whether aprocess is under control.
11. Internal and External Audit Program for the duration of theproject.
2.05 INSPECTION PROCEDURES
A. As a minimum, inspect work before beginning each worksegment and after completing a representative portion of thework.
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B. Perform follow up inspections as necessary to ensure compliancewith the contract documents.
C. Preparatory inspection shall include:
1. Review of the contract requirements
2. Review of approved shop drawings and submittal data.
3. Check availability of required control testing.
4. Ensure materials and equipment conform to approvedshop drawings and submittal data.
5. Ensure the necessary preparatory work has been completedand is of acceptable quality.
D. Perform an initial inspection as soon as a representativesegment of the particular item of Work has been completed.
1. This inspection shall include the following:
a. Conduct scheduled tests.
1. Results shall cite the Contract requirements, the testor analytical procedures used, and the actual testresults.
2. State whether item tested or analyzed conforms orfails to conform.
3. Test reports shall be signed by the laboratoryrepresentative authorized to sign certified testreports.
4. Immediately deliver all documents to the EmployerRepresentative.
b. Examine quality of workmanship.
c. Check for omissions or dimensional errors.
d. Approve or reject initial work.
E. Provide follow-up inspections as necessary.
1. Include continued testing and examinations to ensurecontinued compliance with the Contract requirements.
F. Prepare and attach to the Inspection procedures copies of
checklists to be used to cover all aspects of the works.
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2.06 INSPECTION AND TEST PLAN
A. Contractor shall develop an Inspection and Test Plan foreach Specification Section and for the design/production/testprocesses for each item of manufactured equipment.
1. Identify the following:
a. All required inspections and tests required by thatSpecification Section
b. Required testing frequency
c. The accept/reject criteria
d. Records required to document compliance
e. Procedures or instruction to be used for control of eachactivity
g. Establish procedures to ensure that test results aresubmitted on time
B. Provide sufficient detail to allow the Employer Representativeand other agencies having jurisdictional authority over thework to identify operations to be inspected by that organization(i.e. Ports, Customs & Free Zone Corporation - CED, DubaiMunicipality, etc).
1. Such operations shall not be bypassed by the Contractor,unless a written waiver is given by the witnessingorganization.
2.07 DOCUMENT AND SUBMITTAL CONTROL
A. Establish written procedures for processing all documents andsubmittals associated with this project.
1. Procedures shall address receipt, filing, safe guarding,processing and transmitting.
2. Establish procedures to ensure documents are preparedand transmitted or distributed in a timely manner.
3. Procedures shall also ensure documents contain therequired technical information.
B. Provide quality control procedures, methods, and currentdocuments at the locations where they are to be used.
C. Maintain separate files for quality related documents andmake such files available to the Employer Representative uponrequest.
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1. Retain all quality related records for not less than tenyears.
2. Protect all records from damage, deterioration, and loss.
D. Contractor shall not change or alter approved submittals,procedures, shop drawings or any other pertinent documentationwithout the Employer Representatives written authorization.
E. Establish document registers to verify the approval status ofITPs, Method Statements and Drawings.
2.08 IDENTIFICATION AND CONTROL OF ITEMS AND
MATERIALS
A. Contractor shall establish control procedures to ensure thatitems or materials accepted through shipping or receivinginspection are properly used and installed.
B. Contractor shall identify all items and materials so that theyare traceable throughout all inspections, test activities, andrecords.
1. For stored items, the identification method shall beconsistent with the expected duration and type of storage.
C. Contractor shall record equipment and material identificationsand ensure that they are traceable to the location where theyare incorporated into the work.
D. Contractor shall develop and maintain a receiving/inspectionlog containing at least the information itemized below:
1. Purchase order number
2. Item number
3. Suppliers name
4. Quantity
5. Item description
6. Reference to applicable Contract requirements
7. Date received
8. Heat number, serial number or other Identification, asapplicable
9. Verification of receipt of all required supportingdocumentation
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10. QC acceptance sign-off and date
11. Non-conformance number, if applicable.
2.09 INSPECTIONS AND TESTS
A. Contractor shall use an approved material testing laboratoryfor testing required by these specifications.
1. An on-site approved independent laboratory accreditedby Dubai Municipality Construction Quality Control &Research Section (DM CQC & RS) and staffed by qualifiedpersonnel shall be used.
a. Submit name and qualifications of independent testinglaboratories to Employer Representative for approvalnot less than 7 calendar days prior to the date thelaboratories are to be used.
b. Once approved, dismissal and replacement of theapproved independent testing laboratory shall requirewritten authorization by the Employer Representative.
B. All inspections, sampling and testing of materials shall beconducted in accordance with the specified standards.
1. Contractor shall have adequate QC personnel on siteduring all production shift operations.
2. Test procedures submitted for approval shall include thefollowing, as a minimum:
a. Prerequisites for the given test
b. Required tools, equipment, and instrumentation
c. Necessary environmental conditions
d. Acceptance criteria
e. Data to be recordedf. Test results reporting forms
g. Identification of items tested
C. Inspection work shall be performed by personnel designatedby the Contractor.
1. Such personnel shall not be the same as those performingthe work.
D. Approved procedures and instructions shall be on hand andused by inspection and test personnel at the time of inspectionor test.
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1. All revisions shall be approved prior to being used toinspect or test the work.
2. No deviations from approved work procedures and
instructions shall be allowed without written authorizationfrom the Employer Representative.
E. Provide the Employer Representative with not less than 24 hourswritten notice of the occurrence of an assigned hold point.
1. Any hold point inspected by outside agencies shall requirea minimum of 14 days prior written notification.
F. Submit inspection/test results to the Employer Representativeprior to incorporating the item(s) into the work.
1. Report inspection/test failures to the EmployerRepresentative immediately upon receipt.
2. Submit certificates of compliance 7 days prior toincorporating a product to the Works.
G. Inspections and tests conducted by persons or agencies otherthan the Contractor shall not in any way relieve the Contractorof his responsibility and obligation to meet all Specificationsand referenced standards.
H. Inspection and test records shall, as a minimum, identify thefollowing:
1. Name of items inspected/tested
2. Quantity of items
3. Inspection/test procedure reference
4. Date
5. Name of inspector/tester
6. Observations/comments
7. Specified requirements
8. Acceptability
9. Deviations/non-conformances
10. Corrective action
11. Evaluation of results
12. Signature of authorized evaluator
I. Inspection and Test Status
1. Contractor shall clearly document and identify theinspections and test status of materials and equipment
throughout construction.
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2. Identification may be by means of stamps, tags, or other
control devices attached to, or accompanying, the material
or equipment.
2.10 MEASURING AND TEST EQUIPMENT
A. Provide measuring and test equipment necessary to ensureconstruction conforms to the requirements of the specification.
B. Maintain the accuracy of all measuring and test equipment.
1. Provide a unique identification number or markpermanently affixed to each item of measuring and test
equipment.2. Calibrate each item of measuring and test equipment at
intervals recommended by the manufacturer and submitcalibration certificates.
3. Develop a log of all measuring and test equipment andrecord:
a. Equipment description
b. Identification number
c. Date of the last calibration
d. Due date of the next calibration
2.11 NON-CONFORMANCE MONITORING
A. Contractor shall develop a system to identify, document, controland process non-conforming material and equipment.
1. A non-conformance exists when either material andequipment, documentation, or construction do not complywith the requirements of the Contract Documents.
2. The monitoring system shall apply to material andequipment as well as documentation, installation andconstruction which fail to conform to the ContractDocuments.
B. Contractor shall provide the Employer Representative with thefollowing information for each non-conformance:
1. Identification of non-conformance
2. Description of non-conformance
3. Evaluation of non-conformance to establish the cause4. Recommended corrective action
5. Date non-conformance was identified
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6. Date corrective action was completed
7. Description of final corrective action
8. Consultants Approval
C. Contractor shall develop and maintain a non-conformanceaction tracking log to track all non-conformances.
1. Log shall contain the following information as a
minimum:
a. Sequential reference number
b. Date issued
c. Originator
d. Description of item deemed to be in non-conformance
f. Description of non-conformance
g. Recommended and final disposition
h. Date closed
i. QC Managers initials
j. Remarks, as applicable
D. Contractors QC personnel shall have the authority to stop thatportion of the work which does not comply with the Contractrequirements.
E. The dispositions for non-conforming items and materials shallbe subject to approval by the Employer Representative.
F. Contractor shall clearly identify each non-conforming item witha status tag or other distinguishing mark.
1. Establish procedures for installing, monitoring, and
removing these status tags.2. Identify personnel authorized to remove status tags.
G. Corrective Actions
1. Contractor shall take prompt action to identify the causesof each non-conformance and the corrective actionnecessary to prevent recurrence.
a. The results of failure and discrepancy report summaries,supplier evaluations, and any other pertinent applicable
data shall be used for determining corrective action.
b. Information developed during construction, tests, andinspections that support the implementation of required
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improvements and corrections shall be used to supportthe adequacy of corrective action taken.
2.12 PERSONNEL QUALIFICATIONS
A. Contractor shall identify activities requiring qualified production,inspection, and test personnel and establish their minimumcompetence level.
B. Personnel inspecting and testing special operations (e.g.,welding, brazing, etc.) shall have the experience, training, andcurrent certification commensurate with the scope, complexity,or nature of the activity.
1. Such personnel shall be approved by the EmployerRepresentative.
C. Contractor shall submit the following for all such production,inspection and test personnel:
1. Qualifications description
2. Orientation
3. Skill evaluation
4. Certification credentials
D. Contractor shall maintain records of personnel qualifications asquality records.
2.13 QUALITY CONTROL REPORTS/AUDITS
A. The Contractors Quality Control Manager shall provide adaily Quality Control Report to the Employer Representative.This report shall be comprehensive and it should include all
Q.C. activities on the project.
B. Contractor shall perform regularly scheduled internal audits toverify that his quality control procedures ensure total compliancewith the Specifications and referenced standards.
1. Schedule quality control audits not less than monthly anddocument findings in a report.
2. Maintain records of internal audits as quality records andmake them available to the Employer Representative uponrequest.
3. Provide the Employer Representative with access to theaudit records upon request.
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4. Allow the Employer Representative to observe theContractors internal audit upon request.
5. Provide the Employer Representative with a copy of theaudit report.
C. Contractor shall perform regularly scheduled external auditson his main Suppliers and Sub-Contractors to verify that theirquality control procedures ensure total compliance with thespecifications and referenced standards.
1. Schedule quality control audits not less than monthly.
2. Maintain records of internal audits of contractors andsubcontractors as quality records and make them available
to the Employer Representative upon request.3. Provide the Employer Representative with access to the
audit records upon request.
4. Allow the Employer Representative to observe theContractors internal audit upon request.
5. Provide the Employer Representative with a copy of theaudit report.
2.14 EQUIPMENT/MATERIAL HANDLING AND STORAGEA. Contractor shall be responsible for handling, storing and
preserving equipment and material from the time of receipt tothe time of acceptance by the Employer.
B. Contractors storage and handling procedures shall bedesigned to prevent damage, deterioration, distortion of shapeor dimension, loss, degradation, loss of identification, orsubstitution.
C. The handling procedures shall address the use, inspection
and maintenance of special devices such as crates, boxes,containers, dividers, slings, material handling and transportationequipment and other facilities.
D. Contractor shall identify equipment and material requiringspecial handling or testing.
2.15 QUALITY CONTROL RECORDS
A. Contractor shall develop a complete records index based onthe requirements for document and data submittals in each
Section of the Specifications.1. Indicate all quality control records, documentation,
submittals and data required by the Contract.
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2. Supplement these records as necessary to monitor qualitythroughout the project.
3. The records identified in the index shall provide objective
evidence that quality control program activities conform tothe contract requirements.
a. Include evidence that required verifications have beenperformed
b. Establish the basis for key project decisions.
B. Authenticate all records.
1. Only complete and properly authenticated documentsshall be maintained as records of material and equipment
quality.
C. Quality records shall be indexed, filed and maintained in amanner that provides for timely retrieval; traceability, easyidentification and the latest status (acceptability) of equipmentand material.
D. Protect Quality Control records from deterioration anddamage.
E. As a minimum, records shall include:1. Name of equipment/material inspected/ tested
2. Specification reference by section and paragraph (whereapplicable)
3. Quantity of items
4. Location and installation
5. Inspection/test procedure reference
6. Date
7. Signature of inspector
8. Observations/comments
2.16 WORKMANSHIP
A. Comply with industry standards except when more restrictivetolerances or specified requirements indicate more rigidstandards or more precise workmanship.
B. Perform work by persons qualified to produce workmanship ofthe specified quality.
C. Secure products in place with positive anchorage devicesdesigned and sized to withstand stresses, vibration, andracking.
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D. Comply with manufacturers published installation instructionsin full detail, including each step in sequence.
1. Should instructions conflict with Contract Documents,
request clarification from Employer Representative beforeproceeding.
2.17 PROTECTION OF PROPERTY
A. Do not load or permit a structure to be loaded in a manner thatwill endanger the structure.
B. Do not subject Work or adjacent property to stresses or pressures
that will endanger it.
C. Existing Surfaces and Facilities:
1. Take positive action to protect existing surfaces and facilitiesfrom damage resulting from construction operations unlessmodifications to the surfaces or facilities are required aspart of the Contract.
2. Protect paving, landscaping, and utility facilities fromdamage caused by mobile and stationary equipment,including vehicles delivering materials to the project site.
3. Protect finished surfaces, including jambs and soffits ofopenings used as passageways through which materialsare handled, against possible damage resulting form theconduct of the work by trades.
4. Provide and maintain adequate protection for adjacentstructures.
a. When required by law or for the safety of the Work;shore, brace, underpin, or otherwise protect thoseportions of adjacent structures that may be affected by
the Work.
D. Utilities
1. Known utilities and related facilities are shown on thedrawings.
a. Location of these facilities are not guaranteed, noris there any guarantee that other utilities are notpresent.
b. Unless otherwise specifically provided, protect utilitiesand related facilities from damage and cause nointerruption of service.
2. Establish and maintain direct contact with the Employer
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Representative or operator of each utility that may beaffected by the Work.
a. Proceed with Work that may affect a utility only withthe cooperation and approval of the EmployerRepresentative or operator of the utility.
b. Immediately inform the Employer Representative ofany agreement with the utility operator concerning the
Work under this Contract.
3. Verify the location of all utilities in the vicinity of the workbefore commencing construction.
a. Submit a plan for performing the work to the EmployerRepresentative for approval.
b. Include evidence of approval by the utility owner oroperator.
E. New Work
1. All finished surfaces shall be clean and un-marred uponacceptance of the area.
2. Do not permit traffic or material storage on finishedsurfaces.
a. Where some activity must take place on the finishedsurface in order to perform the Work, provide andmaintain adequate protection.
3. Provide and maintain adequate protection against theweather at all times so as to preserve Work, materials,equipment, apparatus, and fixtures free from damage.
4. Do not use items of equipment that are intended to forma part of the completed work as construction equipmentwithout specific approval from the Employer Representativein each instance.
2.18 QA/QC INDUCTION TRAINING
A. Prepare and carry out QA/QC Induction Training for all QCstaff, Engineers, Inspectors and Foremen on the project QCplan, procedures, Inspection and Test Plan, method statementsand checklists to be used during the construction of theproject.
B. Prepare and carry out QA/QC Induction Training for all Sub-Contractors staff as noted in A.
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Section 3 : RECOMMENDED PRACTICES BEFORE AND DURING CONCRETING
3.01 FORMWORK
All forms should be perfectly cleaned
Release agent applied correctly Correct position
Line and level
Accuracy within tolerances
Verticality (plumb)
Correct angles for batters
Finishing heights (mark off)
Joints flush and tight
Joints sealed as required
No nails protruding into the concrete
3.02 CONCRETE CONSOLIDATION
Make sure you can see the concrete surface
When inserting the poker, its head should be put in quickly andallowed to penetrate to the bottom of the layer as quickly as
possible under its own weight. If done slowly, the top layer willbe compacted first, making it more difficult for the entrappedair in the lower part of the layer to escape to the surface.
The head should be inserted vertically. This minimizes the voidscreated by inserting the head, and allows air bubbles to rise upunimpeded by a sloping vibrator.
The poker should be left in the concrete for about 10 seconds,and withdrawn slowly.
The poker should not touch the form face.
The poker should extend 100mm into any previous layer.
The maximum depth of the new layer equals the vibrator headlength minus 100mm. If the depth of concrete is greater, thenthe new part will not be fully compacted.
It should be noted that where finish is important, extra vibrationcan reduce the number of blowholes.
3.03 CONCRETING Someone experienced in the construction of formwork should
always be present at site when the concrete is being placed.
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Grout loss is an indication that joints were not tight or somemovements have occurred during placing.
In walls and columns no layer should be more than about450mm thick. With layers thicker than 450mm, the weight ofconcrete on top makes it impossible even with vibration to getthe air out from the bottom of the layer.
Make sure that each layer of concrete has been fully compactedbefore placing the next one.
Fully compacted concrete will be dense, strong, durable andimpermeable. Badly compacted concrete will be weak, nondurable, honeycombed and porous. The air must be removed.
For maximum compaction, preferance should be given to the
use of self compacting concrete.
3.04 HOT WEATHER CONCRETING
The American Concrete Institute Hot Weather Concreting, ACI305R-99, defines hot weather as any combination of high ambienttemperature, high concrete temperature, low relative humidity,high wind speed, and excessive solar radiation that can impair thequality of fresh or hardened concrete. These factors individually orcombined, can accelerate moisture loss and cement hydration.
Concrete mixed and placed during hot weather is subject toconditions that can adversely affect the properties and serviceabilityof the hardened concrete. Some of these conditions are:
Increased water demand
Increased rate of slump loss
Increased rate of setting
Increased tendency of plastic shrinkage cracking anddrying shrinkage cracking
Low ultimate strength
Decreased durability Increased permeability
Increased potential for reinforcing steel corrosion
Successful hot weather concreting requires careful planning andclose coordination among all members of the construction team.Best results will be achieved if the following important proceduresare recognized.
A. Production at Batching Plants
1. Shading the aggregates.
2. Cooling the mixing water before use.3. Approved water cementitous material ratio should be
respected.
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4. Set retarding admixtures can be added to slow setting ofconcrete and reduce water demand.
5. Cement extenders, such as Fly Ash and GGBS.
B. Transport
1. Steady flow of concrete
2. Drum rotation should be at the lowest agitating speed
3. Major placement of concrete should be scheduled duringevening or night times and periods of lower traffic.
4. The dispatching of trucks should be coordinated with therate of placement to avoid delays in arrival or long waiting
periods.5. Traffic arrangement at site should ensure easy access of
delivery units to the unloading points.
6. Site traffic should be coordinated for a quick turnaroundof concrete truck.
C. Placement of Concrete
1. Have adequate manpower and equipment (plus stand-byunits) available to handle the concrete at the desired rate
of placement and to unload the concrete trucks promptly.2. Water should be available in sufficient quantities. The
temperature of water used for curing must be as close aspossible to that of the concrete to avoid thermal shock (notmore than 11 C than that of concrete).
3. Erect temporarily windbreaks and shades to protect freshconcrete from hot sun and drying winds.
4. Arrangement should be made for the ready availability ofbackup equipment for placing, vibrating and material for
curing.5. Dampen the sub grade, forms and reinforcing steel the
night before, do this again thoroughly before placingconcrete.
6. Cover concrete as soon as it is placed, until final finishingcan be started.
7. Water curing should start immediately after finishing andit should be continuous as per specified period of curing.
8. Temperature of concrete should be as per specified limit.
9. For mass concrete a method statement should be givenaddressing the logistical and technical issues.
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D. Testing
1. An approved trained technician should perform all tests.
2. Leaving the samples of fresh concrete exposed to sun,wind or dry air is not acceptable.
3. Samples of fresh concrete shall be provided withan impervious cover, cured and stored in a shadedenvironment (temperature of shaded environment shouldbe as per relevant standards). Record temperature usingmaximum minimum thermometer.)
4. Prevent moisture loss of samples during transportationby wrapping them in plastic wet burlap. Be sure to avoidexcessive rough handling during transportation to the
laboratory.
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Section 4 : SCHEDULE OF TESTS AND INSPECTIONS
CAST IN-SITU CONCRETE
Ready-Mixed Concrete
LABORATORY & PLANT TRIAL MIXES
Schedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES
A. Composition/Selection Each Grade Before Production Starts
Concrete Temperature ASTM C 1064 Each grade
Slump
BS 1881-102,
EN 12350-2 Initially and every 15 minutes
Flow Table(1) EN 12350-5 Initially and every 15 minutes
Slump Flow(2) ASTM C 1611 Each grade
T-50 cm Slump Flow(2) ASTM C 1611 Each grade
V-Funnel(2)European Guidelines
for SCCEach grade
V-Funnel at T5minutes(2)
European Guidelinesfor SCC
Each grade
L-Box (h2/h
1)(2)
European Guidelinesfor SCC
Each grade
J-Ring(2) ASTM C 1621 Each grade
Fresh Concrete Density& Yield
BS 1881-107, EN12350-6, ASTM C 138
Each grade
Air ContentBS 1881-106,
EN 12350-7Each grade
Bleeding ASTM C 232 Each grade
Setting Time ofConcrete
ASTM C 403 Each grade
Compressive StrengthBS 1881-116,EN 12390-3
At 7 and 28 days for eachgrade
Tensile/FlexuralStrength
EN 12390-5&6At 7 and 28 days for grades
where flexural govern
Drying Shrinkage ASTM C 596 Each grade of structuralconcrete
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DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES
Sulfate and Chloride
ContentBS 1881-124 Each grade (3)
Rapid ChloridePenetration
ASTM C 1202At 28 days for each grade of
structural concrete
Water Absorption BS 1881-122At 28 days for each grade of
structural concrete
Water Permeability EN 12390-8At 28 days for each grade of
structural concrete
Initial SurfaceAbsorption Test
BS 1881-208At 28 days for each grade of
structural concrete
(1) Where flowable concrete is used
(2) Where Self Compacting Concrete is used
(3) Whenever the source of any ingredient changes
Notes:
1. Designed concrete shall conform to the requirements specifiedin EN 206 and BS 8500
2. Additional testing will be conducted at the request of theEngineer and/or Authority
3. Contract Specifications are to be implemented if more or othertests are required
4. Follow the recommendations of the following codes/standards:
ACI 311.5: Guide for concrete plant inspection and testing ofready-mixed concrete
ACI 304R: Guide for measuring, mixing, transporting and
placing concreteASTM C94/C94M: Standard Specification for Ready MixedConcrete
The European Guidelines for Self Compacting Concrete
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CAST IN-SITU CONCRETE
Ready-Mixed Concrete
CONCRETE PRODUCTION & SITE DELIVERIES
Schedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES
A. Composition/Selection Structural Concrete
Concrete Temperature ASTM C 1064 Each load
SlumpBS 1881-102,EN 12350-2
Each load
Flow Table(1) EN 12350-5 Each load
Slump Flow (2) ASTM C 1611 Each Delivery650 - 750 mm
and visually
J-Ring (2) ASTM C 1621As per projectspecifications
0 - 10 mm
Fresh Concrete Density& Yield
BS 1881-107,EN 12350-6,ASTM C 138
With each set of compressivestrength cubes
Air Content (3)BS 1881-106,
EN 12350-7
Each load
Compressive StrengthBS 1881-116,EN 12390-3
1. Critical Structures (columns, cantilevers...): One set every 10m3or
fraction thereof
A setconsistsof atleast 6cubes
2. Intermediate Structures: One set every 50m3or
fraction thereof
3. Mass Concrete (rafts): One set every 100m3for
pours less than 2000m3
One set every 150m3forpours less than 2000m3
Tensile/FlexuralStrength
EN 12390-5&6At 7 and 28 days for grades where
flexural govern
Evaluation of StrengthTest Results of Concrete
ACI 214,ACI 363.2R
Biweekly for each grade of structuralconcrete:1. The overall variation class of
operation for general constructiontesting shall be at least Good.
2. The within-test variation class ofoperation for field control testingshall be at least Very Good.
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DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES
Visual Examination of
Aggregates (by washing)
Project Specifications At the request of the Engineer
Sulfate and ChlorideContent
BS 1881-124 As per project specifications
Rapid ChloridePenetration
ASTM C 1202 As per project specifications
Water Absorption BS 1881-122 As per project specifications
Water Permeability EN 12390-8 As per project specifications
Initial SurfaceAbsorption Test
BS 1881-208 As per project specifications
(1) Where flowable concrete is used
(2)Where Self Compacting Concrete is used
(3) Where air-entrained concrete is used
Notes:
1. A strength test is the average strength of concrete specimens sampled
from the same batch or load.2. A load is the quantity of concrete transported in a vehicle comprising
one or more batches.
3. A batch is the quantity of fresh concrete produced in one cycle ofoperations of a mixer or the quantity discharged during one minutefrom a continuous mixer.
4. Follow the recommendations of ACI 305R during hot weather.
5. Follow the recommendations of the following codes/standards:
ACI 311.5: Guide for concrete plant inspection and testing of ready-
mixed concrete
ACI 304R: Guide for measuring, mixing, transporting and placingconcrete
ASTM C94/C94M: Standard Specification for Ready Mixed Concrete
6. Each load shall be accompanied by a computer controlled nonsimulated printout listing all the information related to the mix.
7. Each truck mixer/agitator, when it arrives at site, shall have its watercontainer full. If that container is not full or field test results are outsidethe specified limits, the load shall be rejected.
8. Additional testing will be conducted at the request of the Engineer and/or Authority
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9. Contract Specifications are to be implemented if more or other tests arerequired.
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CAST IN-SITU CONCRETE
SITE LABORATORIES
Requirements for Concrete Testing Laboratories
A. Human Resources:
a. The testing lab services shall be provided under the technicaldirection of a professional engineer with relevant experiencein construction material testing, or a supervising lab technicianwith relevant experience in construction material testing andcurrent technician certification.
b. The testing field and/or lab technician shall possess currenttechnician certification or have undergone a training programcovering all the relevant tests performed by the technician.
B. Test Methods and Procedures:
a. The site testing laboratory shall be capable of performing therequired tests as per standard methords, guides or practices.
b. The laboratory shall use the latest version of each referencedmethod within one year of its publication unless an earlier
version of the standard is required by the client.
c. Laboratory personnel shall have convenient access to applicablestandards.
C. Facilities, Equipment and Supplemental Procedures:
a. The laboratory shall have facilities and equipment conformingto the requirements of the applicable test methods.
b. All equipment and instruments shall be verified and calibrated
before being placed in service and at the frequency set by thepertinent standards and local regulations.
c. All balances and scales shall be calibrated annually or wheneveraccuracy is in doubt.
D. Preparations and Conditions:
a. Proper sampling of fresh concrete shall be conductedin accordance with the pertinent standards and project
specifications.b. The required field tests shall be performed at the frequencies
stated in the project specifications.
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c. The floor, where tests are preformed and compressive strengthspecimens are stored, shall be levelled and free of anyvibrations.
d. Concrete test specimens shall be protected from evaporationand damage.
e. Proper tagging of the specimens shall be done specifying thedate, time, location, grade of concrete and name of technicianmoulding the specimens.
f. Initial curing temperatures for the concrete specimens shall bemaintained between the limits set in the pertinent standards.
g. De-moulding of the concrete specimens shall be done withinthe time limitations stated in the relevant standards.
h. Curing tanks shall be of sufficient size and controlledtemperature. Temperature shall be verified with recordingthermometers.
E. Laboratory Records and Reports:
The laboratory shall maintain a system of records that permitsverification of any issued report. The records shall include:
a. Standard operating procedures
b. Calibration certificates of the equipment and instrumentsused
c. Records on laboratory personnel that document workexperience, competency and certification
d. Current standard test methods
All testing reports shall include the information requiredand stated by the pertinent standards and test methods.
All testing reports shall state the acceptance criteria of the testbeing carried out as well as a statement on whether the test
results passed or failed.
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CAST IN-SITU CONCRETEReady-Mixed Concrete
AGGREGATESSchedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY/ NOTES
A Composition/Selection Coarse Aggregate Fine Aggregate
Grading EN 933-1, BS 812-103
Daily Daily Material finer than0.075mm sieve
EN 933-1, BS 812-103
Water Absorption andSpecific Gravity
ASTM C 127, C 128,EN 1097-6
Twice a month
Elongation and FlakinessEN 933-3&4,BS 812-105
Monthly
Moisture Content in Sandby Moisture Tester (Speedy)
To be carriedout by
batching plant
Cleaning ofmoisture tester
regularly
Moisture Content ofwashed aggregates and ofaggregates in rainy seasons
ASTM C 566 At least three times a day
Clay Lumps and FriableParticles
ASTM C 14 Monthly
Light Weight Particles ASTM C 123 Every 3 months
Organic Impurities ASTM C 40 Monthly
Sand Equivalent ASTM D 2419 Monthly
Water Soluble Chlorides(Quantitative)
BS 812-117 Every three months
Acid Soluble Sulfates BS 812-118 Every three months
Soundness (MgSO4) - 5
cyclesASTM C 88 Every two months
Potential Reactivity ofAggregates
ASTM C 289, C 227 Every six months
Aggregate DryingShrinkage
EN 1367-4 Every six months
10% Fines Value (TFV)BS 812-111, EN
1097-2Every two months
Los Angeles Abrasion Test ASTM C 131 Every two months
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Notes:
1. All the tests shall be done before the start of the work and whenever
the source is changed.
2. Additional testing will be conducted at the request of the Engineerand/or Authority.
3. Contract Specifications are to be implemented if more or other testsare required.
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CAST IN-SITU CONCRETEReady-Mixed Concrete
WATERSchedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY/ NOTES
A Composition/Selection
Chlorides (Cl) ASTM D 512
Initially, everythree
months, andwhenever
source changes
It shall complywith the
requirements ofASTM C1602 /
EN 1008
Sulfates (SO4) ASTM D 516
Alkali Carbonates andBicarbonates ASTM D 513
Total Dissolved Ions ASTM D 1888
pH value ASTM D 1293
Notes:
1. Additional testing will be conducted at the request of the Engineerand/or Authority.
2. Contract Specifications are to be implemented if more or other testsare required.
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CAST IN-SITU CONCRETEReady-Mixed Concrete
CEMENTITIOUS MATERIALS & ADMIXTURESSchedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY/ NOTES
Cement EN 197, ASTM C 150 Initially and every three months
GGBS BS 6699, ASTM C 989 Initially and every one month
Pozzolanic Fly ash BS EN 450S Initially and every three months
Silica Fume ASTM C 1240 Initially and every three months
Liquid Admixtures ASTM C 494, C 260, C 1017 Initially and every three months
Notes:
1. All the cementitious materials shall conform to the physical andchemical requirements of the pertinent standard specifications. Therequired tests shall be made to verify compliance.
2. For cementitious materials, regular sampling shall be made fromeach delivery for random testing. All samples are to be stored until
28 or 56 day results are obtained and satisfactory.3. Additional testing will be conducted at the request of the Engineer
and/or Authority.
4. Contract Specifications are to be implemented if more or other testsare required.
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BORED IN-SITU PILES AND DRILLED SHAFTS
Schedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY / NOTES
A Composition/Selection
Reinforcing Steel BS EN 10080Refer to frequency of testing of Steel in
this Manual
Concrete Concrete SpecificationsRefer to frequency of testing of Cast-
in-place Concrete in this Manual
Pile Load Test ASTM D 1143
Minimum 1% for each type (Dimensionof Piles Diameter and Length) or as
per project specifications ifmore tests are required
Pile Load Test ASTM D 4945Minimum 5% of Piles or as per
project specifications if more tests arerequired
Pile Integrity Test ASTM D 5882 All Piles
Cross Hole LoggingAnalyzer
ASTM D 6760Minimum 10% of Piles or as per
project specifications if more tests arerequired
Calliper Logging ASTM D 6167Minimum 10% of Piles or as per
project specifications if more tests arerequired (To be selected randomly)
Ultimate Load Test ASTM D 1143A minimum of one non-working pile
to be tested according to projectspecifications
Notes:
1. Additional testing will be conducted at the request of the Engineer
and/or Authority.2. Contract Specifications are to be implemented if more or other tests
are required.
3. For Diaphragm Wall the following instruments are to be fixed formonitoring purpose:
Inclinometer, Steel Strain gauges, concrete stress gauges, andpressure cells.
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REINFORCING STEEL
Schedule of Tests and Inspections
DESIGNATION NORMATIVEDOCUMENT
FREQUENCY NOTES
A Composition/Selection
Grade 460 B & Other Grades BS EN 10080
Mechanical Properties
Yield Strength
Ultimate Strength
Elongation of Fracture
Mass / meter
Nominal Cross-sectionalArea
Bending
Re-bending
Chemical Properties
One (1) set of tests
for Mechanicaland ChemicalProperties for eachbar diameter at thestart of the job andevery 100 tons ofsteel delivered tothe site.(Refer to Notes)
1. Every consignmentof Steel shall haveMill Certificates tobe attached to theMaterial InspectionRequest for theEngineers review.Steel tags havingheat number are tobe provided with thesteel.
2. Tests are to berepeated wheneverthere is a change inthe source of supply.
Notes:
1. All steel reinforcement specified shall comply with BS 4449 or BS4483, and shall be cut and bent in compliance with BS 8666.
2. Additional testing will be conducted at the request of the Engineerand/or Authority.
3. Contract Specifications are to be implemented if more or other tests
are required.4. Reinforcing steel, supplied by Cares or equivalent accredited
certification body approved mills, shall be tested at the start of theproject and every 200 tons delivered to site.
5. Reinforcing steel, supplied and processed by Cares or equivalentaccredited certification body approved steel mills and cutting &bending companies, shall be tested at the start of the work andevery 400 tons delivered to site.
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EPOXY-COATED STEEL
Schedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES
Coating Thickness
BS 7295 /ASTM A775
As per standard/project
specifications
Every consignment ofSteel shall have Mill& Test Certificates tobe attached to theMaterial Inspection
Request for theEngineers review.
Steel tags having heatnumber are to be
provided with the steel
Coating Continuity
Coating Flexibility
Coating Adhesion
Notes:
1. Additional testing will be conducted at the request of the Engineerand/or Authority.
2. Contract Specifications are to be implemented if more or other testsare required.
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EARTHWORK
Schedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES
Particle Size Analysisand Determination ofSoil Constants(Dry and Wet)
BS 1377 part 2
All tests shall becarried out at a
minimum rate of 3tests for every 300m3
of material
ProjectSpecifications
Atterberg Limits (LL,PL & PI)
BS 1377 part 2
Sand Equivalent ASTM D 2419
Chlorides andSulfates in Soil BS 1377 part 3
In-Situ Density of Soil
a. Trenches
BS 1377
a) Make at selected locations at leastone field density test for every 200m2area/layer, but in no case less thanthree(3) tests per day operation.
b. Walkways
b) Make at selected locations at least
one field density test of subgrade orfinish grade for every 200m2area,but in no case less than three (3) testsper day operation.
c. Pavement Layer(Subgrade, Subbaseand Base)
c) Make at selected locations at leastone field density test for every 200m2area/layer, but in no case less thanthree (3) tests per day operation
Moisture - DensityRelations of Soil using4.5 kg Rammer, 457mm Drop Method D
BS 1377 part 4 All required testsshall be carried outfor every 400 m3of
material
ProjectSpecifications
California Bearing
Ratio Test
BS 1377
Notes:
1. Additional testing will be conducted at the request of the Engineerand/or Authority.
2. Contract Specifications are to be implemented if more or other testsare required.
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PRECAST CONCRETE
Schedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES
1 Material TestingRefer to the requirements of the Cast-
in-place Concrete and Reinforcing Steelsections of this Manual
ProjectSpecifications
2 Testing finished Material
CompressiveStrength
BS 1881,BS EN 12390-3
As directed by theEngineer (Cores fromprecast units) Project
SpecificationsDurabilityRequirements
As directed by theEngineer (Cores fromprecast units)
3 Joint Sealant and Fillers
Cement Grout(Portland Cement)
BS EN 197As directed by theEngineer
ProjectSpecifications
Natural Sand BS EN 13139
Non-shrink GroutAs directed by theEngineer
Elastomeric SealantsASTM C 962,
ACI 504
4Inserts and OtherHardware
ASTM A 307, A 325,A490, A 108, A 496
ProjectSpecifications
Corrosion Protection ASTM A 276Project
SpecificationsExpansion Anchors ASTM E 448
Notes:
1. Additional testing will be conducted at the request of the Engineerand/or Authority.
2. Contract Specifications are to be implemented if more or other testsare required.
3. Follow the recommendations of the manuals published by pci,Precast/Prestressed Concrete Institute.
SECTION 4 : SCHEDULE OF TESTS AND INSPECTIONS
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GLASS REINFORCED CEMENT (GRC) ELEMENTS
Schedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES
1 Composition of GRC Elements
Glass ContentProject
Specifications
At the start of the
job, once a month
or as requested by
the EngineerWet Bulk Density
2 Testing finished Material
Modulus of RuptureProject
Specifications
At the start of thejob, once a month
or as requested by
the Engineer
ProjectSpecificationsLimit of Proportionality
JJ the EngineerLloyd T 5000/SS
Notes:
1. Additional testing will be conducted at the request of the Engineerand/or Authority.
2. Contract Specifications are to be implemented if more or other tests
are required.
3. Works and Material shall comply with the following requirements:
a. PCI MNL 117 - Manual for Quality Control for Plants andProduction of Architectural Pre-cast Construction Products
b. PCI MNL 128 - Recommended Practice for Glass Fibre ReinforcedConcrete Panels
c. PCI MNL 130 - Manual for Quality Control
SECTION 4 : SCHEDULE OF TESTS AND INSPECTIONS
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CONCRETE BLOCKS
Schedule of Tests and Inspections
DESIGNATION NORMATIVEDOCUMENT
FREQUENCY NOTES
1 Masonry Blocks
Dimensions and CompressiveStrength
DubaiMunicipality
StandardEvery 20,000 blocksDensity
Chloride and Sulfate Content
2 Paving Blocks
Dimensions and CompressiveStrength
DubaiMunicipality
StandardEvery 20,000 blocksDensity
Chloride and Sulfate Content
3 Filler Blocks (Normal Weight)
Dimensions and CompressiveStrengthDubai
MunicipalityStandard
Every 20,000 blocksDensity
Chloride and Sulfate Content
4 Filler Blocks (Light Weight)
Dimensions and CompressiveStrength
Dubai
MunicipalityStandard Every 20,000 blocksDensity
Chloride and Sulfate Content
Notes:
1. Additional testing will be conducted at the request of the Engineerand/or Authority.
2. Contract Specifications are to be implemented if more or other tests
are required.3. Works and Material shall conform to Dubai Municipality and
International Standards.
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AUTOCLAVED AERATED CONCRETE BLOCKS
Schedule of Tests and Inspections
DESIGNATIONNORMATIVE
DOCUMENTFREQUENCY NOTES
A Composition/Selection
AAC Blocks
Dimensions and CompressiveStrength
Dubai Municipality
Standard
Every 20,000
blocks
Thermal Conductivity and DryDensity
Chloride and Sulfate Content
Drying Shrinkage
Fire Rating ASTM E 119Project
Specifications
MortarProject
Specifications
As recommendedby the
manufacturer
Portland Cement:
Works below Ground Slab (SRC) BS 4248
Project SpecificationsWorks above Ground Slab (OPC) BS EN 197-1
Sand BS EN 13139 Project Specifications
AccessoriesAs directed bythe Engineer
Project Specifications
Notes:
1. Additional testing will be conducted at the request of the Engineerand/or Authority.
2. Contract Specifications are to be implemented if more or other testsare required.
3. Works and Material shall conform to Dubai Municipality andInternational Standards.
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NORMAL WEIGHT CONCRETE POLYSTYRENE SANDWICH BLOCKS
Schedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES
A Composition/Selection
Dimensions and CompressiveStrength
Dubai MunicipalityStandard
Every 20,000blocks
Thermal Conductivity
Chloride and Sulfate Content
Apparent Density
Polystyrene Dimensions andDensity
Polystyrene Core ThermalConductivity
Fire Rating (Polystyrene)ASTM D 2863,BS EN 11925-2
As directedby the
Engineer
ProjectSpecifications
Mortar Project SpecificationsAs recommended
by the
manufacturer
Portland Cement:
Works below Ground Slab (SRC) BS 4248
Project SpecificationsWorks above Ground Slab (OPC) BS EN 197-1
Sand BS EN 13139 Project Specifications
AccessoriesAs directed by
the EngineerProject Specifications
Notes:
1. Additional testing will be conducted at the request of the Engineerand/or Authority.
2. Contract Specifications are to be implemented if more or other testsare required.
3. Works and Material shall conform to Dubai Municipality andInternational Standards.
SECTION 4 : SCHEDULE OF TESTS AND INSPECTIONS
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LIGHT WEIGHT MASONRY UNITS
Schedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES
A Composition/Selection
Dimensions and CompressiveStrength
Dubai MunicipalityStandard
Every 20,000blocks
Thermal Conductivity
Gross Density
Chloride and Sulfate Content
Drying Shrinkage
Fire Rating ASTM E 119As directed
by theEngineer
ProjectSpecifications
Mortar Project SpecificationsAs recommended
by themanufacturer
Portland Cement:
Works below Ground Slab (SRC) BS 4248
Project SpecificationsWorks above Ground Slab (OPC) BS EN 197-1
Sand BS EN 13139 Project Specifications
AccessoriesAs directed by
the EngineerProject Specifications
Notes:
1. Additional testing will be conducted at the request of the Engineerand/or Authority.
2. Contract Specifications are to be implemented if more or other testsare required.
3. Works and Material shall conform to Dubai Municipality andInternational Standards.
SECTION 4 : SCHEDULE OF TESTS AND INSPECTIONS
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CLAY MASONRY BLOCKS WITH POLYSTYRENE INSERT
Schedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES
A Composition/Selection
Dimensions and CompressiveStrength
Dubai MunicipalityStandard
Every 20,000blocks
Thermal Conductivity of Block
Thermal Conductivity ofThermal Insulation
Density of Thermal Insulation
Water Absorption
Apparent Density
Block Efflorescence
Fire Rating (Polystyrene)ASTM D 2863,BS EN 11925-2
As directedby the
Engineer
ProjectSpecifications
Mortar Project SpecificationsAs recommended
by themanufacturer
Portland Cement:
Works below Ground Slab (SRC) BS 4248
Project SpecificationsWorks above Ground Slab (OPC) BS EN 197-1
Sand BS EN 13139 Project Specifications
Accessories As directed bythe Engineer Project Specifications
Notes:
1. Additional testing will be conducted at the request of the Engineerand/or Authority.
2. Contract Specifications are to be implemented if more or other testsare required.
3. Works and Material shall conform to Dubai Municipality andInternational Standards.
SECTION 4 : SCHEDULE OF TESTS AND INSPECTIONS
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LATH AND PLASTER
Schedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES
Cement Plaster
Portland CementBS 12, 146, 215,
4027 and BS 5224
As directedby the
Engineer
ProjectSpecifications
Lime BS 890
Sand BS 1199
Aggregates BS 882
Water BS 3148
Ready Mix RenderingMaterial
BS 4721
Bagged RenderingMaterial
BS 5262
Plaster Accessories BS 5262
Pull-Off Test BS 1881-207
Notes:
1. Additional testing will be conducted at the request of the Engineerand/or Authority.
2. Contract Specifications are to be implemented if more or other testsare required.
3. Works and Material shall conform to the following codes:
Code of practice for External Rendered Finishes BS 5262Code of practice for Internal Plastering BS 5492
Code of practice for Plastering and Rendering BS 8000 Part 10
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POLYSTYRENE THERMAL INSULATION
Schedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES
Compressive Strength andDimensions
Project SpecificationsAs directed
by the
Engineer
Thermal Conductivity
Density
Water Absorption
Flexural Strength
Water Vapour Permeance
Dimensional Stability
Oxygen Index
Notes:
1. Additional testing will be conducted at the request of the Engineer
and/or Authority.
2. Contract Specifications are to be implemented if more or other testsare required.
3. Works and Material shall conform to Dubai Municipality andInternational Standards.
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PAINTING
Schedule of Tests and Inspections
DESIGNATION NORMATIVE DOCUMENT FREQUENCY / NOTES
Specific Gravity ASTM D 1650
Project Specification / asrequired by the Engineer
Solid Content ASTM D 2139
Drying Time ASTM D 1650
Adhesion Strength ASTM D 4541
Abrasive Strength ASTM D 4060
Impact ASTM D 2794
Hardness ASTM D 2240
Crack Bridgeability ASTM D 836
Non Volatile Matter ASTM D 2939
Fungus Resistance ASTM D 2734
UV Resistance ASTM 653
Salt Spray Resistance ASTM B117
SECTION 4 : SCHEDULE OF TESTS AND INSPECTIONS
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SECTION 5 : QC FORMS
NON-CONFORMANCE REPORT
Project : ___________________________________________________________________________
Client : _________________________________________ NCR No. : _____________________
Project Manager : _________________________________________ Date : _____________________
Consultant : _________________________________________
Contractor : _________________________________________ Location : _____________________
Sub-Contractor : _________________________________________ Category : _____________________
Non-Conformance:
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
Issued by: _________________ Signature: ___________________
Requirements
Specifications : ___________________________________________________________________________
Standards : ___________________________________________________________________________
Drawings : ___________________________________________________________________________
Other : ___________________________________________________________________________
Received by Contractor/Sub-Contractor:Name: ________________ Position: ________________ Signature: _____________ Date: ______________
Cause of Non-Conformance:
____________________________________________________________________________________________
Name: ________________ Position: ________________ Signature: _____________ Date: ______________
Proposed Corrective Action by Contractor/Subcontractor:
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
Name: ________________ Position: ________________ Signature: _____________ Date: ______________
Comments by Project Manager/Consultant:
Accept: Accept with comments: Reject:
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
Name: ________________ Position: ________________ Signature: _____________ Date: ______________
Corrective Action Completed/Verified:
QA/QC Manager Name: ________________ Signature: _____________ Date: ______________
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STATUSOFNON-
CON
FORMANCEREPORTS
Proje
ct
:______________________________________________________
_________________________________
____________________________________
Clien
t
:______________________________________________________
_
NCRReportNo.:________________________________
Proje
ctManager:______________________________________________________
_
Date
:_
____________________________________
Cons
ultant
:______________________________________________________
_
Cont
ractor
:______________________________________________________
_
Location
:_
____________________________________
Sub-Contractor:______________________________________________________
_
Category
:_
____________________________________
NC
RRef.
No.
Date
Issued
Description
Contractor
Consultant/ProjectManag
er
Date
Received
Date
Returned
Accepted/
Date
Rejected
/
Date
SECTION 5 : QC FORMS